Sun visor assembly having a rounded edge

A sun visor assembly, comprising:

• a substantially flat foundation folded unto itself thereby forming two foundation halves, said halves having corresponding shapes that define an edge of said sun visor;
• an upholstery cover covering said foundation and forming an exterior surface of said sun visor;
• a bead member disposed proximate said edge, said bead member comprising a surface having a semicircular cross section, said surface facing away from said sun visor, whereby said bead member defines a radius;
• and
• said bead member further comprising a plurality of stakes extending therefrom, said stakes being heat fused to said foundation and securing said bead member thereto.

A sun visor assembly, comprising:

• a substantially flat foundation folded unto itself thereby forming two foundation halves, said halves having corresponding shapes that define an edge of said sun visor;
• an upholstery cover covering said foundation and forming an exterior surface of said sun visor;
• and
• a core member disposed substantially between said halves;
• said core member including a rounded member located on the perimeter of said sun visor assembly, said rounded member disposed proximate said edge and having a surface comprising a substantially semicircular cross section.